TM RACING 2010 STROKE 250 Workshop Manual Download Page 1

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www.tmracing.it

Ed.01 - 02/2020

250-300

MX - EN - SMX
SMR

- 2020

Workshop Manual

4 STROKE ENGINE

Summary of Contents for 2010 STROKE 250

Page 1: ...www tmracing it Ed 01 02 2020 250 300 MX EN SMX SMR 2020 Workshop Manual 4 STROKE ENGINE...

Page 2: ......

Page 3: ...UR HANDS THOROUGHLY AFTER HANDLING THE OIL WEAR LATEX GLOVES OR EQUIVALENT DURING MAINTENANCE WORK ON THE MOTORCYCLE OIL IS HIGHLY POLLUTANT THEREFORE AFTER USE IT MUST BE DISPOSED OF AT SPECIAL COLLE...

Page 4: ...h electric start E S as well as kick start K S MX SMX models have K S as standard and may be equipped with E S as an option Please make a note of your motorcycle s serial numbers in the boxes below Wh...

Page 5: ...and piston removal 45 2 5 2 Strap and oil scraper replacement and mounting 46 2 5 3 Cylinder and piston coupling 46 2 5 4 Cylinder and piston re mounting 46 2 5 5 Compression check 48 2 6 TEMPERATURE...

Page 6: ...73 2 22 RATCHET HOLDER GEAR REMOVAL 74 2 22 1 Ratchet holder gear and gearbox drive shaft clearance adjustment 75 2 23 SEMICASE 76 2 23 1 Aperture 76 2 23 2 RE ASSEMBLY 77 2 24 CRANKSHAFT GEARBOX GEAR...

Page 7: ...light alloy Segments 1 segment 1 oil scraper Lubrication 2 oil pumps 1 for delivery 1 for recovery Engine oil SAE 10W 50 Engine oil amount oil change engine overhaul 1 25 1 35 litres Straight tooth g...

Page 8: ...ck cylinder and piston wear Replace piston completely Check head Check camshafts and rocker arms Replace valves springs half cones and plates Replace piston rod completely Check clutch discs Check clu...

Page 9: ...ents or their housing in the piston worn Replace 3 Excessive accumulation of carbon deposits in the combustion chamber or on the piston crown Clean 4 Rocker arm worn Replace 5 Excessive valves play Ad...

Page 10: ...correct valves play Adjust 7 Valve seats or guides faulty Replace 8 Valves springs weakened or seized Replace The engine overheats 1 Combustion chamber and or piston crown encrusted with carbon residu...

Page 11: ...7 1 ADJUSTMENTS REPLACEMENTS...

Page 12: ...be removed in order to access disassembly of the head cover For the sake of convenience the images shown below refer to an engine positioned on a workbench Unscrew the screws 1 from the head cover 2 R...

Page 13: ...ver 9 Check the status of the gasket 10 replace it if worn Position the gearbox in neutral Using a socket wrench 11 turn the crankshaft to position the piston at top dead centre as indicated by the ti...

Page 14: ...camshaft 13 and the valve pad is 0 15mm 0 006 in Use a thickness gauge 17 to check the play between the exhaust cams 18 of the intake camshaft 14 and the valve pad is 0 20 mm 0 008 in Otherwise the p...

Page 15: ...lacement In case it is necessary to replace the spring of the valve lifter pin work as follows After dismounting the exhaust camshaft 1 unscrew the screw 2 and remove the plate 3 Extract the spring 4...

Page 16: ...sition the piston at top dead centre rotating the crankshaft via the closed end spanner 2 NOTE Before remounting the camshafts check that the gasket 3 is not worn replace it if necessary Mount the int...

Page 17: ...centring pins in their corresponding seats Remove the comparator 1 Mount the clamp 8 by inserting the centring pins in their corresponding seats Screw the screws 9 alternately without tightening then...

Page 18: ...wo crescents 10 Check that the gaskets 11 and 12 located on the head cover 13 are not worn Replace them if necessary Mount the head cover 13 by screwing the screws 14 crosswise and then tightening the...

Page 19: ...the motorcycle on a flat surface and prepare a suitable recipient under the same Loosen the introduction cap 3 positioned on the right side of the engine clutch cover and the drain caps 4 and 5 posit...

Page 20: ...asure with the amount of the prescribed engine oil necessary see table and pour from the introduction hole Repeat the oil level check operation Check sealing of the filter cover introduction and drain...

Page 21: ...REPLACEMENT Drain the engine oil as described in the relative paragraph Unscrew the M5 L65 1 and M5 L25 2 screws then remove the clutch cover 3 Remove the gasket 4 Unscrew the screws 5 of the clutch...

Page 22: ...f 1 8 mm the other discs have thickness of 1 5 mm Remount the pressure plate 7 with the relative springs 6 Re mount the screws 5 and tighten them crosswise and gradually with a torque of 8 Nm 0 8 kgm...

Page 23: ...sc pack removal Drain the engine oil as described in the relative paragraph Unscrew the M5 L65 1 and M5 L25 2 screws then remove the clutch cover 3 together with the corresponding gasket Tighten the c...

Page 24: ...20 8 9 9 10 11 ADJUSTMENTS REPLACEMENTS Remove the pressure plate 8 Unscrew the nut 9 Remove the nut 9 and the washer 10 Remove the complete clutch pack 11...

Page 25: ...ns 4 and remove the upper drum 4a Extract the disk pack 12 1 5 2 Discs replacement and re mounting of clutch Mark the position of the arrow 13 on the lower drum 14 which must coincide with the positio...

Page 26: ...lined and that the first two smooth discs have thickness of 1 5 mm the other discs have thickness of 2 mm The clutch pack must finish with a smooth disc Mount the lined disc 15 with smaller lining tha...

Page 27: ...19 11 ADJUSTMENTS REPLACEMENTS Mount the disk pack 18 on the lower drum 14 Mount the upper drum 4a making the arrow 19 coincide with arrow 13 of the lower drum and then tighten the columns 4 Mount the...

Page 28: ...LACEMENTS Insert the safety washer 10 and the nut 9 Tighten the nut 9 with a torque of 100 Nm 10 kgm 73 75 ft lb Loxeal 82 33 Lock the nut by raising the tabs of the lock washer 10 Mount the pressure...

Page 29: ...n the screws 5 with a torque of 8 Nm 0 8 kgm 5 9 ft lb Remove the columns 4 supplied Mount the clutch guard 3 and relative gasket replace it if worn and tighten the screws 1 ML L65 and 2 ML L25 gradua...

Page 30: ...26 ADJUSTMENTS REPLACEMENTS...

Page 31: ...27 2 ENGINE DISASSEMBLY...

Page 32: ...E COMPONENTS LAYOUT 1 Cylinder head cover 2 Cylinder head 3 Chain tensioner 4 Cylinder 5 Starter motor 6 Throttle body connection coupling 7 Temperature sensor 8 Transmission cover 9 Oil filter 10 Wat...

Page 33: ...ion cover casing as described in the relative paragraph Remove the seeger ring 1 and the pinion 2 Slide the bushing 3 out NOTE On re mounting the bush 3 check the status of the O ring gasket 4 and rep...

Page 34: ...oner removal Unscrew the plug 1 and remove it Remove the gasket 2 and replace it remounting it on the plug 1 Unscrew the chain tensioner plug 3 and remove it Remove the copper washer 4 replace it and...

Page 35: ...he chain tensioner 5 come out Remove the chain tensioner 5 from the vice and press it manually until end of stroke checking that it slides without obstacles Further press the chain tensioner 5 and rel...

Page 36: ...linder use a screwdriver for positioning Press the chain tensioner 5 until you hear the last click Grease the chain tensioner 5 using grease Insert the chain tensioner 5 in the seat of the cylinder Ma...

Page 37: ...d making sure you replaced the copper washer 4 Tighten the plug 3 with a tightening torque of 33 Nm 3 3 kgm 24 34 ft lb Use a punch 9 to push the chain tensioner so that the mobile part is re leased w...

Page 38: ...nd the chain tensioner as de scribed in the corresponding paragraphs Unscrew the three screws 1 of the timing system drive gear cover 2 Screw a 6 mm screw 3 on the cover 2 Remove the cover 2 by means...

Page 39: ...the timing system drive gear steady 7 The bushing 8 must come out together with the needle roller bearing 9 Remove the chain 10 from the drive gear 7 Recover the rear shim 11 Completely remove the dr...

Page 40: ...lateral nuts 12 at the left of the head Unscrew the nuts 13 of the head studs exhaust side and collect the corresponding washers 14 Unscrew the nuts 15 of the head studs intake side and collect the co...

Page 41: ...k all components in a way to re mount the exactly in the same place from where they were removed Retrieve the pads 1 if they have not been already removed Unscrew the screw 2 of the left intake rocker...

Page 42: ...e status of the OR gasket 7 replace it if worn Screw an M5 screw 8 remove the pin 9 and recover the right intake rocker arm 10 Screw an M5 screw M5 11 on the pin 12 and remove the rocker arms 13 exhau...

Page 43: ...gaskets or of the combustion chamber Make sure that the separator tool is upright otherwise the valve stem may bend Remove the tool and remove the double spring 15 and the relative valve 16 NOTE Befor...

Page 44: ...gasket 19 and the oil seal 17 Lubricate the components with engine oil Use engine oil to lubricate the valve stem 16 and insert it into the valve guide paying attention not to pinch the oil seal 17 Mo...

Page 45: ...nscrew the M5 screw 11 Lubricate the pin 9 of the right intake rocker arm 10 with engine oil and remount it in the same exact position and unscrew the screw 8 Lubricate the pin 4 of the left intake ro...

Page 46: ...that the OR gasket 7 has been replaced Remount the pads 1 in the same position from which they have been removed 2 4 4 Head re mounting Position the centring bushings 1 on the stud bolts 2 Replace the...

Page 47: ...hem with a torque of 20 Nm 2 0 kgm 14 75 ft lb Step two tighten with a torque of 32 Nm 3 2 kgm 23 60 ft lb Step three tighten with a torque of 48 Nm 4 8 kgm 35 40 ft lb NOTE It is recommended to repla...

Page 48: ...corresponding inter nal shim 10 Correctly place the timing chain 8 on the drive gear 9 Keep the drive gear 9 in position lubricate the pin 12 and the bearing 11 with engine oil and mount the drive in...

Page 49: ...LINDER AND PISTON 2 5 1 Cylinder and piston removal Remove the head as described in the relative section Remove the cylinder 1 by sliding it from the stud bolts Remove the lock ring 2 of the piston 3...

Page 50: ...part of the strap 6 of the spacer 3 and of the rings 4 and 5 as indicated in the figure before re mounting the piston in the cylinder 2 5 3 Cylinder and piston coupling If the piston must be replaced...

Page 51: ...e connecting rod head 6 with the aid of an aluminium punch 8 Mount the retaining ring 9 Completely insert the cylinder 2 in the stud bolts 10 by inserting the two sliders NOTE If the cylinder or the p...

Page 52: ...pper surface of the cylinder and zero Move the pushrod 4 of the micrometer on the top flat part of the piston first on intake side then exhaust side and detect the dimension Correct compression 0 55 0...

Page 53: ...unscrew the three screws 2 at the moment of remounting use Three bond 1215 paste and screw the screws 2 with a tightening torque of 1 5 Nm 0 15 kgm 1 11 ft lb 2 9 HEAD COOLING CONNECTION REMOVAL Unscr...

Page 54: ...oval with relative command rod Unscrew the screws 1 and remove the actuator 2 and the pinion protection 3 Unscrew the screw 4 and remove the bracket 5 Slide the mushroom 6 out NOTE On re mounting chec...

Page 55: ...re mounting lubricate the gaskets and seal with clutch oil Re mount everything proceeding in the opposite order to disassembly Tighten the screws 1 with a torque of 8 Nm 0 8 kgm 5 9 ft lb 2 11 GEAR S...

Page 56: ...1 and M5 L25 screws 2 Remove the flywheel cover 3 Remove the gasket 4 Retrieve the two centring bushes 5 NOTE On re mounting check that the two centring bushes 5 are positioned correctly and that the...

Page 57: ...he rubber cap 5 is fitted correctly on the cover and then tighten the two screws 3 of the stop plate 4 with a torque of 4 Nm 0 4 kgm 2 95 ft lb 2 12 3 Pick up Unscrew the two screws 1 and remove the p...

Page 58: ...y Block rotor rotation 1 and use an impact gun to loosen the nut 2 with relative curve washer Screw the extractor 3 onto the thread of the rotor 1 and tighten the screw 4 to detach the rotor 1 from th...

Page 59: ...Re mounting Re mount everything proceeding in the opposite order to disassembly making sure to Remount the sliders 9 together with their corresponding spacers 10 by screwing the screws 8 with a tight...

Page 60: ...e flywheel cover as described in the relative section Remove the idler 1 with the relative roller bearing cage Remove the idler 2 with the relative roller bearing cages Unscrew the screw 3 and remove...

Page 61: ...57 6 5 7 6 ENGINE DISASSEMBLY Tighten the M5 screw 5 onto the bush 6 and tighten until the bush 6 moves forward Remove the starter motor 7...

Page 62: ...ce it if ruined Lubricate the gasket 9 and the gaskets 8 with engine oil and then mount the starter motor 7 Use an aluminium or brass punch to push the bush 6 towards the inside of the engine making t...

Page 63: ...cages and lubricating with engine oil Re mount the idler 1 with the relative roller bearing cage and lubricating with engine oil 2 14 WATER PUMP NOTE If water escapes from the little hole 1 the pump...

Page 64: ...screwdriver to remove the seal 9 NOTE Lubricate the seal 9 with engine oil before mounting it Re mount the impeller 8 tightening with a torque of 6 Nm 0 6 kgm 4 42 ft lb greasing the thread Re mount...

Page 65: ...TRANSMISSION GUARD Unscrew the screws 1 1a M5 L25 screw 1b M5 L30 screw 1c M5 L65 screw 1d M5 L45 screw 1e M5 L50 screw Remove the guard 2 with the aid of a rubber hammer Remove the gasket 3 and reco...

Page 66: ...h water pump disassembled NOTE On re mounting first mount the bearing 6 and then the seal 7 lubricating it with engine oil 2 15 2 Seal and oil passage bored disc removal Remove the seeger 8 the seal 9...

Page 67: ...rface of the lid and the semicase from any residues Check that the two centring bushes 4 are in their respective housing Replace and re mount the gasket 3 Mount the water pump return 2 on the cover 5...

Page 68: ...STARTER REMOVAL ONLY K S Remove the transmission cover and the clutch bell as described in the relative paragraphs Release the spring 1 from the relative housing turn the starter 2 anti clockwise by 1...

Page 69: ...E Lubricate the fitting hole abundantly with graphite grease 2 17 DRUM AND CLUTCH BELL 2 17 1 Disassembly Remove the transmission cover as described in the relative paragraph Remove the clutch discs a...

Page 70: ...66 3 5 6 7 8 ENGINE DISASSEMBLY Remove the drum 3 Remove the washer 5 Remove the bell 6 Remove the two roller bearings 7 and the spacer 8...

Page 71: ...ing Insert the washer 9 Re mount everything proceeding in the reverse order to disassembly Make sure that the spacer 8 and ball bearings cage 7 are re mounted correctly and lubricate them with engine...

Page 72: ...e mounted the bell 6 and the drum 3 make sure the safety washer 2 has been positioned correctly Screw the nut 4 blocking drum rotation with a spanner with torque of 100 Nm 10 0 kgm 73 75 ft lb strong...

Page 73: ...1 Oil pump return gear 2 Idle gear kick starter removal 3 Kick starter only for K S 4 Gearbox primary shaft 5 Gearbox command shaft 6 Ratchet holder gear 7 Oil pump 8 Crankshaft gear Remove the seeger...

Page 74: ...shim 14 and the gear 2 Remove the roller bearing cage 15 and the shim 16 NOTE To re mount the gears and relative roller bearing cages proceed in reverse order to disassembly and lubricate with engine...

Page 75: ...20 OIL PUMP REMOVAL Remove the clutch bell and the oil pump return gear as described in the relevant paragraphs Unscrew the screws 1 Remove the pump 2 by lifting it Remove the two centring pins 3 Remo...

Page 76: ...9 Remove the two internal sectors 10 11 and the dragging pin Extract the shaft 12 by pushing it Remove the seeger 13 the washer 14 and remove the spring 15 of the oil maximum pressure valve NOTE On r...

Page 77: ...tled release the spring 2 from the contrast pin 3 and remove it with the relative bush 4 To remove the pin 3 loosen the nut 5 with relative washer 6 NOTE To re mount proceed in reverse order to the di...

Page 78: ...LDER GEAR REMOVAL Remove the gearbox command shaft and the oil pump return gear as described in the relevant paragraphs Unscrew the two screws 1 Unscrew the two screws 2 Remove the plate 3 and the pla...

Page 79: ...shaft and the other on the ratchet holder gear are aligned Tighten the screw 1 with a torque of 10 Nm 1 0 kgm 7 37 ft lb and screws 2 with a torque of 10 Nm 1 0 kgm 7 37 ft lb medium threadlocker blu...

Page 80: ...s on the flywheel side and transmission side as described in the relative paragraphs 2 23 1 Aperture Unscrew the screws 1 1a M6 L55 screw 1b M6 L50 screw 1c M6 L35 screw Use a rubber hammer to open th...

Page 81: ...torque of 12 Nm 1 2 kgm 8 68 ft lb 1a M6 L55 screw 1b M6 L50 screw 1c M6 L35 screw 2 24 CRANKSHAFT GEARBOX GEARS DRUM Open the guards as indicated in the relative section 2 24 1 COMPONENTS POSITION 1...

Page 82: ...act the secondary shaft fork pin 7 Release the forks 8 and 9 of the secondary shaft from the selector drum and remove them Slide the primary shaft fork pin 10 out Use a screwdriver to move the ratchet...

Page 83: ...ve the complete gear assy 14 2 24 5 Primary shaft gear sequence 2a Primary shaft 2b First 2c Fifth 2d Third 2e Fourth 2f Sixth 2g Second 2 24 6 Secondary shaft gear sequence 3a Secondary shaft 3b Firs...

Page 84: ...again and applying Loxeal 82 33 on the thread 2 24 9 Components re mounting Re mount the components proceeding in reverse order to disassembly lubricating with engine oil and when re mounting the gear...

Page 85: ...NOTE...

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